Austempered Ductile Iron for successfully lightweight designed components

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1 Austempered Ductile Iron for successfully lightweight designed components Oscillating suspension arm for special vehicles In cooperation with Industrie Cometto S.p.A. ADI JS/ Substitution of a welded assembly Increased load capacity of the vehicle Increased competitiveness

2 Austempered Ductile Iron for successfully lightweight designed components Company overview What s ADI ADI Advantages ADI Applications Oscillating Arm for Special Vehicles

3 Company Overview General information 3 Minerbe (Verona, Italy) 60km from Verona Airport 120km from Venice Airport 240km from Milano Airport

4 Company Overview General information Foundation Year

5 Company Overview General information Employees

6 Company Overview General information smq Total Surface Area 50% covered

7 Company Overview General information Ton Foundry Capacity

8 Zanardi Facilities 8 LABORATORY FINAL TESTING MACHINING SHOP PAINTING SHOP FOUNDRY AUSTEMPERING HEAT TREATMENT CORE SHOP ENGINEERING DEPARTMENT

9 Zanardi Facilities Engineering Department 9 Design and Co-Design ProE CAD & ProE FEM Magmasoft

10 Zanardi Facilities Foundry 10 Moulding Line Dimensions: 710x900x( )mm Weight Range: kg

11 Zanardi Facilities Foundry 11 Melting Plant 3 Melting induction furnace 28 ton per furnace

12 Zanardi Facilities Foundry 12 Pouring Line With automatic Transfer Ladle

13 Zanardi Facilities Austempering Heat Treatment 13 Equipment 3 AFC-Holcroft UBQA All our austempering treatment has been done internally since 2001.

14 Zanardi Facilities Austempering Heat Treatment ton Heat Treatment Capacity All our austempering treatment has been done internally since 2001.

15 Zanardi Facilities Austempering Heat Treatment 15 Additional Service Heat Treatment in Subcontracting All our austempering treatment has been done internally since 2001.

16 Zanardi Facilities Machining Shop 16 Machining Nr. 3 Vertical Lathe Hyundai Hit V5 Nr. 4 Robotised platform Nr. 2 Workstation

17 Zanardi Facilities Laboratory Final Testing 17 Chemical & Mechanical Lab.

18 Zanardi Facilities Laboratory Final Testing 18 Testing machines for fatigue

19 Company Overview Materials 19 Standard Materials Ductile Iron

20 Company Overview Materials 20 Standard Materials Ductile Iron Austempered Ductile Iron (ADI)

21 Company Overview Materials 21 Standard Materials Ductile Iron Austempered Ductile Iron (ADI) NEW Austempered Materials Austempered Grey Iron (AGI)

22 Company Overview Materials 22 Standard Materials Ductile Iron Austempered Ductile Iron (ADI) NEW Austempered Materials Austempered Grey Iron (AGI) Austempered Steel

23 Company Overview Materials 23 Standard Materials Ductile Iron Austempered Ductile Iron (ADI) NEW Austempered Materials Austempered Grey Iron (AGI) Austempered Steel Zanardi Patented Materials ADI Wear Resistance (ADIWR)

24 Company Overview Materials 24 Standard Materials Ductile Iron Austempered Ductile Iron (ADI) NEW Austempered Materials Austempered Grey Iron (AGI) Austempered Steel Zanardi Patented Materials ADI Wear Resistance (ADIWR) Isothermed Ductile Iron (IDI)

25 Ductile Iron Austempering What s ADI Austempered Ductile Iron Ductile Iron and Alloys Perlitic and Ferritic Matrix obtained AS-CAST 25 Heat Treatment in Salt Bath ADI Austempered Ductile Iron Acicular Ferrite in stabilized austenitic structure

26 Austempering Cycle 26

27 What s ADI Advantages 27 LIGHTNESS

28 What s ADI Advantages 28 COMPLEX DESIGN SHAPES

29 What s ADI Advantages 29

30 What s ADI Advantages 30 WEAR RESISTANCE

31 What s ADI Advantages 31 FATIGUE

32 What s ADI Advantages 32 RECYCLABILITY

33 Market 33 Earth Movement Gears & Transmissions Trucks, Busses and Coaches Agriculture Automotive Concrete and Mining Plant Railway Compressors, hydraulics and oleodynamics

34 Market Automotive 34 STATIONARY BRAKE TONGSBEARINGS ADI Raw weight: 2-3 Kg Increased durability STATIONARY BRAKE PLATES ADI Raw weight: 3-4 Kg Increased durability

35 Market Automotive 35 SUSPENSION ARM ADI900-8 Raw weight: 7 Kg Material saved -1,2Kg STEERING KNUCKLES ADI900-8 Raw weight: 9 Kg Material saved -2,1Kg

36 Market Trucks, Busses and Coaches 36 SUSPENSION FOR HEAVY TRUCKS ADI o IDI Raw weight: Kg Improved durability SUSPENSION ARMS FOR BUSES ADI Raw weight: Kg Improved durability

37 Market Gears & Transmissions 37 PLANET CARRIER SOLID SHAFT ADI & ADI900-8 Raw weight: Kg Improved durability PLANETARY HOUSING ADI & ADI900-8 Raw weight: 5-70 Kg Improved durability

38 Market Agriculture 38 SPINDLE ADI Raw weight: 90 Kg Weight reduction -15Kg Material saved -35 Kg CLUTCH DRUM ADI Raw weight: 3-5 Kg Reduced weight and costs

39 Market Agriculture 39 COUPLING SYSTEM ADI Raw weight: Kg Improved durability ROTATOR ADI900-8 Raw weight: 20 Kg Reduced weight Improved durability

40 Market Earth Movement 40 U/C CHAIN LINK FOR TRACK LAYER ADI Raw weight: 1-7 Kg Wear resistance U/C SPROCKET ADI1050-6; ADI1200-3; ADI1400-1; ADI Raw weight: 3-40 Kg Wear resistance

41 Market Concrete and Mining Plant 41 HAMMER ADI1050-6; ADI Raw weight: 5-70 Kg Wear resistance CONCRETE PUMP ROTOR ADI1600-1; ADIWR Raw weight: 3-5 Kg Wear resistance

42 Market Concrete and Mining Plant 42 COVER ADI1600-1; ADIWR Raw weight: 2-4 Kg Wear resistance COVER AND PLATE FOR MIXER ADI1600-1; ADIWR Raw weight: 6-10 Kg Wear resistance

43 Market Compressors, Hydraulics and Oleodynamics 43 PUMP HEAD IDI Raw weight: 2-70 Kg Improved durability PUMP CASE AGI Raw weight: Kg Wear resistance

44 Oscillating Suspension Arm Partnership 44 Industrie Cometto S.p.A. Modular Vehicle manufacturer Lifting platforms Theoretically infinite axles Several tons of load capacity Chemical plants Wind power generation Off-shore platforms

45 Oscillating Suspension Arm 45 Component Description Oscillating suspension arm for MSPE Vehicle Hydraulic suspension Height change up to 700 mm 4 axles and 6 axles 40 ton/axle Project target increase load capacity up to 50 ton/axle +25%

46 Oscillating Suspension Arm Design Solutions 46 S355JR 40 ton/axle version Welded assembly of 8 parts Material R P0.2 R m A 5 S690QL [N/mm 2 ] [N/mm 2 ] S690QL % S355JR % Total weight 99 Kg Due to narrow spaces, it was not possible to increase resistant sections of the component to reach 50 ton/axle Options Substitute S690QL with S890QL Substitute welded assembly with one single ADI casting

47 Oscillating Suspension Arm Material selection 47 WELDED ASSEMBY Material R P0.2 R m A 5 [N/mm 2 ] [N/mm 2 ] S890QL % JS/ % ADI CASTING Selection criteria Tensile behavior Fatigue behavior Machinability Final component cost

48 Oscillating Suspension Arm Tensile properties 48

49 Oscillating Suspension Arm Tensile properties 49 ADI 800 PW WM BM-TL BM-LT S890QL PW: Plane samples BM-TL: Base material taken in orthogonal direction by welding beam BM-LT: Base material taken in parallel direction by welding beam WM: Samples taken on welding beam

50 Oscillating Suspension Arm Tensile properties 50 ADI JS/ ADI JS/ CrMo4 Wrought G25CrMo4

51 Oscillating Suspension Arm FEM Calculations 51 WELDED ASSEMBY 40 ton version ADI CASTING 50 ton version

52 Oscillating Suspension Arm Fatigue properties 52 Δσ 0 /2 [N/mm 2 ] Separately cast specimens Si2.6%; Mn0.15%; 200 Nod/mm 2 Machined test probes - Ø6,5 - Rotating Bending R= -1 - PS 50% - Run Out 5 Million Cycles - Short Stair case DI IDI DI y = 0,6985 HB + 207,3 R2 = 0,9819 DI ADI 42CrMo4 QT S690QL BASE ADI S890QL BASE S890QL JOINT R P0.2 [N/mm 2 ] S690QL and S890 are taken from literature work and converted from PB to RB with 0.8 load mode factor

53 Oscillating Suspension Arm 53 Threshold Crack Initiation Value

54 Oscillating Suspension Arm 54 Threshold Crack Initiation Value 24 Separately cast specimens Si2.6%; Mn0.15%; 200 Nod/mm 2 Machined test probes - Ø6,5 - Rotating Bending R= -1 - PS 50% - Run Out 5 Million Cycles - Short Stair case DK TH [MPa * m^0,5] DI IDI ADI ADI 42CrMo4 QT 12 y = 0,0983HB - 11,929 DI R2 = 0, R P0.2 [N/mm 2 ]

55 Oscillating Suspension Arm 55 Fatigue Comparison with cast steel

56 Oscillating Suspension Arm 56 Fatigue Comparison with cast steel ADI JS/900-8/C STEEL CASTING G25CrMo4QT

57 Oscillating Suspension Arm 57 Fatigue in case of casting skin Δσ g, th 1000 Machined Kitagawa Curve Machined El Haddad Curve Un-Machined Kitagawa Curve 100 K L Layer without defects = ΔK TH =16,10 [Mpa m 0,5 ] 10 a 0 Bulk Estimated a 0 Layer = 300 μm α 2 a

58 Oscillating Suspension Arm Technology comparison 58 WELDED ASSEMBY ADI CASTING Complex manufacturing Preparation machining operations Additional heat treatments Controls of welded joints Limited fatigue resistance High stress concentration on joints Easier manufacturing Reduced machining operations No additional treatments Fatigue resistance Optimized design to avoid stress concentrations Effect of casting skin to be considered

59 Oscillating Suspension Arm Conclusions 59 Oscillating suspension arm ADI casting was successfully adopted Increasing 25% the load capacity with only 2% more weight Better fatigue behavior and good machinability Cost reduction thanks to easier manufacturing process

60 60 Thanks for Your attention Light weight Solutions Hall 6, Stand D44 Contacts Ph: Address Via Nazionale, Minerbe, (Verona) Italy

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